Facing and faced insulation products

ABSTRACT

A facing laminate for insulation products includes: a foil or metallized polymeric film sheet layer forming an inner layer of the laminate that is adapted be bonded directly to a surface of an insulation product; a paper composite sheet layer, which may include synthetic and/or inorganic fibers, forming an outer exposed layer of the laminate; and a scrim intermediate and bonded to the foil or metallized polymeric film sheet and paper composite sheet layers. The facing laminate may include a humectant and/or a water, oil, and/or grease repellant component. The paper composite sheet layer of the laminate exhibits greater dimensional stability and reduced wrinkling when the laminate is exposed to conditions of high humidity. Insulation products to be faced with this facing laminate include pipe insulation, duct board, duct wrap insulation, metal building insulation, and other building insulation products.

This application is a division of application Ser. No. 11/517,059, filedSep. 7, 2006 now U.S. Pat. No. 7,749,923. The subject invention relatesto a FSK facing sheet material laminate for insulation products and toinsulation products faced with the FSK facing sheet material laminate.When the term “FSK facing sheet material laminate” is used herein, theterm refers to a facing sheet material laminate that includes a foil ormetallized polymeric film layer, a scrim, a paper or paper compositesheet layer, and an adhesive.

BACKGROUND OF THE INVENTION

More specifically, the FSK facing sheet material laminate of the subjectinvention relates to a FSK facing sheet material laminate that offersopportunities for increased productivity and manufacturing costreductions and that: exhibits enhanced dimensional stability and reduceddeformation and wrinkling (“dimpling”); mold and mildew growthresistance; stain resistance; improved tape adhesion, improved ease ofcleaning, enhanced flame spread resistance; good handleability; UVresistance; surface abrasion resistance; and overall good surfaceaesthetics prior to and during service. The FSK facing sheet materiallaminates of the subject invention may include one or more humectant(s);one or more water, oil, and/or grease repellant components; and/or apaper composite sheet of the paper composite sheet layer that includessynthetic and/or inorganic fibers so that when the facing sheet materialis exposed to conditions of high heat and humidity (e.g. temperaturesequal to or greater than 75° F. and relative humidities equal to orgreater than 50%), the paper composite sheet layer of the FSK facingsheet material laminate exhibits enhanced dimensional stability andreduced deformation and wrinkling (“dimpling”). Preferably, the FSKfacing sheet material laminate of the subject invention includes one ormore flame retardants, fungi growth inhibiting agents, and/or otheradditives to enhance the performance of the laminate and the adhesive ofthe FSK facing sheet material laminate includes synthetic fibers and/orinorganic fibers to further enhance the dimensional stability andstiffness of the paper composite sheet layer and further reducedeformation and wrinkling (“dimpling”) of the paper composite sheetlayer when the FSK facing sheet material laminate of the subjectinvention is exposed to conditions of high heat and humidity. It is alsocontemplated that the paper composite sheet of the paper composite sheetlayer may contain only synthetic and/or inorganic fibers and nocellulose fibers for dimensional stability and stiffness and reduceddeformation and wrinkling (“dimpling”) of the paper composite sheetlayer when the FSK facing sheet material laminate of the subjectinvention is exposed to conditions of high heat and humidity. The facedinsulation products of the subject invention that are faced with the FSKfacing sheet material laminate of the subject invention include pipeinsulation, duct board, duct wrap insulation, metal building insulation,and other building insulation products.

Current commercially available FSK facing sheet material laminates havean aluminum foil or metallized polyester film sheet forming an innerlayer of the laminate, a kraft paper sheet forming an outer exposedlayer of the laminate, a scrim intermediate the foil or metallizedpolyester film sheet layer and the paper sheet layer, and an adhesivethat bonds the foil or metallized polyester film sheet layer, the scrimlayer, and the paper sheet layer together. In use, the aluminum foil ormetallized polyester film sheet forming the inner layer of these FSKfacing sheet material laminates is bonded directly to a surface of aninsulation product and the kraft paper sheet forming the outer layer ofthese FSK facing sheet material laminates becomes the visible surface ofthe faced insulation product. When these FSK facing sheet materiallaminates are exposed to conditions of high heat and humidity, the foilor metallized polyester film layer of these FSK facing sheet materiallaminates remains dimensionally stable while the kraft paper sheet layerof these FSK facing sheet material laminates absorbs moisture andexpands. Furthermore, the aluminum foil or metallized polyester filmlayer of these FSK facing sheet material laminates is typically stifferor more rigid than the kraft paper sheet layer of the laminates. Sincethe dimensionally stable, more rigid, foil or metallized polyester filmlayer and the kraft paper sheet layer of these FSK facing sheet materiallaminates are bonded together, the expansion of the kraft paper sheetlayer relative to the dimensionally stable foil or metallized polyesterfilm layer under conditions of high heat and humidity causes the kraftpaper sheet layer to deform and wrinkle. This deformation and wrinklingof the kraft paper sheet layer adversely affects the visible surface ofa faced insulation product by changing the visible surface from a smoothvisibly pleasing surface to a surface having a visually unappealingmottled finish that can resemble the dimples on a golf ball. Thisvisually unappealing mottled finish is commonly called “dimpling” in theindustry.

Since the faced surfaces of many FSK faced insulation products remainexposed and many FSK faced insulation products, especially pipeinsulation products, are frequently exposed to numerous cycles of highheat and humidity, there has been a need to provide a FSK facing sheetmaterial laminate with an exposed paper or paper composite sheet layerthat is more dimensionally stable and, preferably, stiffer or more rigidthan the kraft paper sheet layers of current FSK facing sheet materiallaminates. In addition, for many applications, there has been a need toprovide a FSK facing sheet material laminate that is more flame spreadresistant and exhibits other desirable characteristics.

SUMMARY OF THE INVENTION

The FSK facing sheet material laminate of the subject invention providesa solution to the problems discussed above in connection with currentFSK facing sheet material laminates. When exposed to conditions of highheat and humidity (e.g. temperatures equal to or greater than 75° F. andrelative humidities equal to or greater than 50%), a kraft paper sheetof a humectant treated FSK facing sheet material laminate of oneembodiment of the subject invention, compared to a non-humectant treatedFSK facing sheet material laminate having a 100% cellulose fiber kraftpaper sheet, absorbs less moisture and thereby exhibits less expansionor greater dimensional stability. When exposed to conditions of highheat and humidity, a non-humectant treated cellulose and glass fibersheet (from 70% to 90% by weight cellulose fibers and from 10% to 30% byweight glass fibers) of a FSK facing sheet material laminate of anotherembodiment of the subject invention, compared to a non-humectant treatedFSK facing sheet material laminate having a 100% cellulose fiber kraftpaper sheet, also exhibits less expansion or greater dimensionalstability. The greater dimensional stability exhibited by the papercomposite sheet layers of the FSK facing sheet material laminates of thesubject invention under conditions of high heat and humidity reduces theinternal stresses otherwise present in previous paper sheet layers ofFSK facing sheet material laminates under these conditions and thedeformation and wrinkling (“dimpling”) of the paper sheet layer causedby such internal stresses. Thus, compared to a non-humectant treated FSKfacing sheet material laminates having a 100% cellulose fiber kraftpaper sheet, the FSK facing sheet material laminates of the subjectinvention better retain their initial, as installed, smooth unwrinkled(“undimpled”) appearance even after being subjected to numerous cyclesof high heat and humidity.

The FSK facing sheet material laminates of the subject invention eachinclude: a foil or metallized polymeric film sheet forming an innerlayer of the laminate that is adapted be bonded directly to a surface ofan insulation product; a paper composite sheet layer forming an outervisible layer of the laminate; a scrim intermediate the foil ormetallized polymeric film sheet and the paper composite sheet layer; andan adhesive bonding the foil or metallized polymeric film sheet, thepaper composite sheet layer, and the scrim together. The FSK facingsheet material laminates of the subject invention may include one ormore humectant(s); one or more water, oil, and/or grease repellantcomponents; and/or a paper composite sheet of the paper composite sheetlayer that includes or is formed from synthetic and/or inorganic fibers.Humectant(s) belong to a family of hydrolyzed fatty acids with singularor multiple hydroxyl groups that prevent or inhibit the absorption ofmoisture by the fibers of the laminate's paper composite sheet toprevent or inhibit expansion of the fibers and the paper composite sheetcaused by the absorption of moisture by the fibers of the sheet. Thehumectants utilized with certain of the FSK facing sheet materiallaminates of the subject invention may include but are not limited to:glycerin, ethylene glycol, polyethylene glycol (PEG200 and PEG400), andisopropylene glycol. The humectant or humectants may be present in thepaper composite sheet layer as coatings and/or saturates and/or in theadhesive of the FSK facing sheet material laminate. The water, oil,and/or grease repellant component(s) may be present in the papercomposite sheet layer of the laminates as coating(s) and/or saturate(s)to impart additional strength, stiffness, and/or water, oil, and greaseresistance to the paper composite sheets.

Preferably, the paper composite sheet layers and/or adhesives of the FSKfacing sheet material laminates of the subject invention include one ormore flame retardants and fungi growth inhibiting agents that make theFSK facing sheet material laminates of the subject invention moreresistant to flame spread and mold or mildew growth. Preferably, thepaper composite sheets of the humectant treated FSK facing sheetmaterial laminates of the subject invention contain synthetic and/orinorganic fibers in addition to cellulose fibers. The synthetic and/orinorganic fibers of the paper composite sheets function to furtherenhance dimensional stability of the paper composite sheets, to stiffenthe paper composite sheets, and to reduce wrinkling of the papercomposite sheets when the FSK facing sheet material laminates areexposed to conditions of high heat and humidity and as discussed above,certain FSK facing sheet material laminates of the subject inventionthat have paper composite sheets containing synthetic and/or inorganicfibers do not contain a humectant. It is also contemplated that thepaper composite sheet may contain only synthetic and/or inorganic fibersand no cellulose fibers.

Faced insulation products that are faced with the FSK facing sheetmaterial laminate of the subject invention include: pipe insulation,duct board, duct wrap insulation, metal building insulation, and otherbuilding insulation products. Due to the frequent exposure of faced pipeinsulation to conditions and cycles of high heat and humidity, the FSKfacing sheet material laminate of the subject invention is particularlywell suited for jacketing jacket pipe insulation products.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of the FSK facing sheet materiallaminate of the subject invention with portions of the laminate brokenaway to better show the different layers of the laminate.

FIG. 2 is a partial schematic perspective view of a jacketed tubularpipe insulation assembly wherein the jacket is made from a FSK facingsheet material laminate of the subject invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, the FSK facing sheet material laminate 20 of thesubject invention includes a paper composite sheet layer 22, a scrim 24,a foil or metallized polymeric film sheet layer 26, and an adhesive 28that bonds the paper composite sheet layer 22, the scrim 24, and thefoil or metallized polymeric sheet layer 26 together. When the facingsheet material 20 is applied to the surface of an insulation product asa facing, e.g. as the jacket of a tubular pipe insulation assembly, thepaper composite sheet layer 22 forms the outer visible surface of thefacing, the foil or metallized polymeric film sheet layer 26 is adheredto the surface of the insulation, and the scrim 24 functions toreinforce the laminate. The FSK facing sheet material laminate 20 istypically manufactured in a continuous laminating process; typically,has a width of about seventy-two inches; and is typically packaged inrolls that are at least 1000 feet in length.

The paper composite sheet layer 22 is typically made of a bleached kraftpaper sheet that, preferably, is between about 30 and 55 pounds/3000square feet and that may include synthetic and/or inorganic fibers andvarious additives; the scrim 24 is made of fiberglass reinforcing yarnsuch as but not limited to a G75 or H110 yarn; and the foil ormetallized polymeric film layer 26 is an aluminum foil between about0.00025 inches and about 0.001 inches in thickness (between about 0.25mils and about 1 mil in thickness) or a metallized polyester filmbetween about 0.48 mils and about 100 mils in thickness (between about48 and 100 gauge in thickness).

While the paper composite sheet forming the paper composite sheet layer22 of the laminate may be a kraft paper sheet (e.g. bleached kraft paperbased sheet) containing only cellulose fibers, the paper composite sheetforming the paper composite sheet layer 22: a) may be a cellulose fiberpaper sheet (e.g. bleached kraft paper based sheet) that includessynthetic and/or inorganic fibers to provide the paper composite sheetlayer 22 with greater dimensional stability and stiffness and to reducethe deformation and wrinkling of the paper composite sheet layer whenthe laminate is exposed to conditions of high heat and humidity; or b) apaper composite sheet containing only synthetic and/or inorganic fibersand no cellulose fibers. Where the paper composite sheet layer 22 is acellulose paper based sheet that includes synthetic and/or inorganicfibers, the paper composite sheet layer 22 typically includes by dryweight:

More Component Broad Range Preferred Range Synthetic and/or 2% to 60% 5%to 40% Inorganic Fibers Humectant(s) 0.1% to 10%   0.1% to 5%   Coatingand/or Saturates (Other 0% to 25% 0.5% to 15%   Than Humectants) ToImpart Strength, Stiffness, and/or Water, Oil, and Grease ResistanceBinder 0% to 15% 0% to 10% Fillers 0% to 30% 0% to 15% FlameRetardant(s) 0% to 25% 0.5% to 25%   Cellulose Fibers RemainderRemainder

Preferably, the synthetic fibers used in the paper sheet layer 22 arebetween about 1 and about 50 Denier (more preferably between about 1 andabout 5 Denier) and have a mean length between 0.25 and 1.50 inches.Examples of synthetic fibers that may be used in the paper sheet layer22 are polyethylene fibers, polypropylene fibers, polyester fibers,polyamide fibers, acrylic fibers, nylon fibers, rayon fibers,carbon-pitch or pyrolized fibers, and/or blends thereof. Preferably, theinorganic fibers used in the paper sheet layer 22 are between about 0.6and about 25 microns in diameter (more preferably between about 0.6 andabout 4 microns in diameter) and have a mean length between 0.25 and 6inches. Examples of inorganic fibers that may be used in the paper sheetlayer 22 are glass fibers, bio-soluble glass fibers, glass micro-fibers,bio-soluble glass micro-fibers, glass blowing wool fibers, chop strandglass fibers, mineral wool fibers, basalt fibers, soluble amorphous woolfibers, refractory ceramic fibers (with and without shot), crystallineceramic fibers, and/or blends thereof. However, other synthetic andinorganic fibers may also be used in the paper sheet provided suchfibers or blends of such fibers with the synthetic and inorganic fiberslisted immediately above provide the paper sheet with greaterdimensional stability and stiffness and reduce the deformation andwrinkling of the paper sheet when the laminate is exposed to conditionsof high heat and humidity. When used in a cellulose fiber paper basedsheet (e.g. bleached kraft paper based sheet) forming the paper sheetlayer 22, the synthetic and/or inorganic fibers of the paper sheet layer22 are imperceptible or substantially imperceptible and do not adverselyaffect the appearance of the paper sheet layer 22.

As discussed above, moisture absorption by the cellulose fibers thekraft paper sheet layers of prior art FSK facing sheet materiallaminates has caused the paper sheet layers of prior art FSK facingsheet material laminates to become dimensionally unstable, expand,deform, and wrinkle when exposed to conditions of high heat andhumidity. Certain embodiments of the FSK facing sheet material laminate20 of the subject invention are treated with one or more humectants toprevent or inhibit the absorption of moisture by the fibers of the papercomposite sheets of the paper composite sheet layers 22 of thelaminates. The one or more humectants utilized with the FSK facing sheetmaterial laminates 20 may include but are not limited to: glycerin,ethylene glycol, polyethylene glycol (PEG200 and PEG400), andisopropylene glycol.

The humectant(s) may be introduced into the paper composite sheet of thepaper composite sheet layer 22 during the paper making process and whenincorporated into the paper composite sheet during the paper makingprocess, comprise between 0.1% and 10% by dry weight of the papercomposite sheet and most preferably comprise between about 0.5% andabout 1% by dry weight of the paper composite sheet.

The humectant(s) may be applied to one or both major surfaces of thepaper composite sheet of the paper composite sheet layer 22, prior tolaminating the paper composite sheet to the other components of the FSKfacing sheet material laminate 20, using spray misting or otherconventional coating techniques and preferably comprise between about0.1 and about 10% by dry weight of the paper composite sheet.

The humectant(s) may be applied to the visible surface of the papercomposite sheet of the paper composite sheet layer 22 as a posttreatment of the formed FSK facing sheet material laminate 20 by spraymisting or other conventional coating techniques and preferably comprisebetween about 0.1 and about 10% by dry weight of the treated or coatedpaper composite sheet.

The humectant(s) may be applied to the visible surface of the papercomposite sheet of the paper composite sheet layer 22, as an ingredientof a surface coating in a post treatment of the formed FSK facing sheetmaterial laminate 20 by spray misting or other conventional coatingtechniques and preferably the humectant(s) comprise between about 0.1and about 10% by dry weight of the coated paper composite sheet. Theother ingredients of the coating would impart strength, stiffness,and/or water, oil, and grease resistance to the coated paper compositesheet and the other ingredients of the coating would include but not belimited to: ethylates or pearl starch PVOH, boric acid cross-linkedPVOH, latex emulsions, acrylic emulsions, PVC emulsions, hydrophilicmodified PET, PE, or PP; and oil and grease resistant chemistries suchas fluorochemicals, tri-valent chromium, silicone, and waxes. The otheringredients of the coating would comprise between about 0.5% and about10% by dry weight of the coated paper composite sheet whereby thecoating of humectant(s) and other ingredients would comprise betweenabout 0.6% and about 20% by weight of the coated paper composite sheet.

A surface coating, other than a humectant, can be applied to the exposedsurface of the paper composite sheet of the paper composite sheet layer22 to impart strength, stiffness and/or water, oil, and greaseresistance to the paper. Such coatings would comprise between about 0.5%and about 10% by dry weight of the coated paper composite sheet andinclude but are not limited to: ethylates or pearl starch PVOH, boricacid cross-linked PVOH, latex emulsions, acrylic emulsions, PVCemulsions, hydrophilic modified PET, PE, or PP; and oil and greaseresistant chemistries such as fluorochemicals, tri-valent chromium,silicone, and waxes.

A saturate can be included in the paper composite sheet of the papercomposite sheet layer 22 to impart strength, stiffness and/or water,oil, and grease resistance to the paper. Such saturates would comprisebetween about 0.5% and about 25% by dry weight of the paper compositesheet and include but not limited to: ethylates or pearl starch PVOH,boric acid cross-linked PVOH, latex emulsions, acrylic emulsions,silicone oil-emulsions, silicone-reactive, siliane-reactive, PVCemulsions, hydrophilic modified PET, PE, or PP; and oil and greaseresistant chemistries such as fluorochemicals including fluoro-silicone,tri-valent chromium, silicone, and waxes. In amounts between about 0.5%and about 10% by dry weight of the paper composite sheet these saturateswould also function as binders. It is contemplated that the surfacecoatings of the immediately preceding paragraph and the saturate(s) ofthis paragraph can both be included in the FSK facing sheet materiallaminate 20 and that the surface coatings and/or saturates would improvethe dimensional stability, moisture resistance, UV stability, and flamespread resistance of the laminate as well as facilitate an easiercleaning of the laminate 20.

The paper composite sheet of the paper composite layer 22 can include abinder or binders such as but not limited to starch. Fillers also may beincluded in the paper composite sheet of paper composite sheet layer 22,such as but not limited to: clay (ball, kaolin, pyrophylite,wolastinite), titania, calcia, magnesia, dolomite, zinc oxide, amorphoussilica, amorphous alumina, fumed or precipitated silica, borax, recycledglass, mica, vermiculite, perlite, and mixtures of any two or more ofthe these fillers. The fillers could function to reduce costs, to blockradiation, and/or to provide UV protection, insect resistance, color,and fire, smoke, and flame resistance.

The paper composite sheet of the paper composite sheet layer 22 may alsoinclude a flame retardant such as but not limited to aluminumtri-hydrate or ATH, which would improve the flame spread resistance ofthe FSK facing sheet material laminate 20 and also function in the papercomposite sheet as a humectant.

As stated above, the scrim 24 is located intermediate and bonded to thepaper composite sheet layer 22 and the foil or metallized polymeric filmsheet layer 26. The scrim is made of a reinforcing yarn, such as but notlimited to G75 of H110 glass fiber yarn, and preferably is from 2 to 6strands per inch in both the machine and cross machine direction with atypical scrim being 5 strands per inch in both the machine and crossmachine direction.

The adhesive 28, which bonds the paper composite sheet layer 22, thescrim 24, and the foil or metallized film sheet layer 26 together, canprovide greater dimensional stability, greater moisture resistance,added stiffness, and/or improved handleability. Examples of adhesivesthat can be used as the adhesive 28 include but are not limited tomaterials, melamine, urea formaldehyde, phenolic, polyurethane, acrylic,latex, and acrylo-nitrile. Additional adhesives that can be used as theadhesive 28, include adhesives that can migrate into the paper compositesheet layer 22 to improve the physical characteristics of the FSK facingsheet material laminate 20 by improving UV stability, flame spreadresistance, opacification, and/or color of the paper composite sheetlayer 22. Examples of such migrating adhesives are colloidal silica oralumina, sodium or potassium silicate, ammonium phosphate stabilizedwith zinc oxide, magnesia or alumina; borax, and oxi-chloride stabilizedwith zinc oxide or magnesia. Of the above adhesives, a latex-laminatingadhesive is the preferred adhesive. While the adhesive layer 28 does notneed to contain fibers, preferably, the adhesive of the adhesive layer28 includes between about 1% and about 5% by weight synthetic and/orinorganic fibers such as but not limited to the synthetic and inorganicfibers and/or blends thereof set forth above for inclusion into thepaper composite sheet of the paper composite sheet layer 22 of thelaminate. Preferably, the adhesive also includes between about 0.5% andabout 30% by weight flame retardant (e.g. aluminum tri-hydrate or ATH),between about 10 ppm and about 100 ppm (0.01 to about 0.10% by dryweight) thiabendazole such as Metasol TK-100 or about 200 ppm and about2000 ppm (preferably between 400 ppm and 600 ppm) 2-(4-Thiazolyl)Benzimidazole (“TBZ”) as a mold and mildew growth retardant, and about9% by dry weight magnesium hydrate to scavenge chlorine and protect thealuminum foil or metallized polyester film sheet from chlorinedegradation. The adhesive 28 may also include one or more humectants inamounts between about 0.1% and about 10% by dry weight.

A preferred embodiment of the FSK facing sheet material laminate 20 ofthe subject invention has or includes: a paper composite sheet layer 22,for providing greater dimensional stability and stiffness and reduceddeformation and wrinkling of the paper composite sheet when the FSKfacing sheet material laminate 20 is exposed to conditions of high heatand humidity, that includes: from about 70% to about 90% by weightcellulose fibers, from about 10% to about 30% by weight glass fibershaving a mean diameter between about 0.6 microns and about 4 microns(e.g. glass fibers having a mean diameter of about 0.65 microns, about2.7 microns, or about 4.0 microns); a glass fiber scrim 24, an aluminumfoil layer 26; and a latex adhesive 28. Another preferred embodiment ofthe FSK facing sheet material laminate 20 of the subject invention hasor includes: a paper composite sheet layer 22, for providing greaterdimensional stability and stiffness and reduced deformation andwrinkling of the paper composite sheet when the FSK facing sheetmaterial laminate 20 is exposed to conditions of high heat and humidity,that includes: from about 70% to about 90% by weight cellulose fibers,from about 10% to about 30% by weight glass fibers having a meandiameter between about 0.6 microns and about 4 microns (e.g. glassfibers having a mean diameter of about 0.65 microns, about 2.7 microns,or about 4.0 microns) and 0.1% to about 10% by dry weight humectantprovided by a humectant containing coating applied at between 1 and 4pounds per 1000 square feet; a glass fiber scrim 24, an aluminum foillayer 26; and a latex adhesive 28. Another preferred FSK facing sheetmaterial laminate 20 of the subject invention has a paper compositesheet layer 22, for providing greater dimensional stability andstiffness and reduced deformation and wrinkling of the paper compositesheet when the FSK facing sheet material laminate 20 is exposed toconditions of high heat and humidity, that includes: from about 70% toabout 90% by weight cellulose fibers and from about 10% to about 30% byweight glass fibers having a mean diameter between about 0.6 microns andabout 4 microns (e.g. glass fibers having a mean diameter of about 0.65microns, about 2.7 microns, or about 4.0 microns); a glass fiber scrim24; an aluminum foil layer 26; and a humectant containing latex adhesive28. The latex adhesive 28 of this FSK facing sheet material laminate 20contains from about 0.1% to about 10% by dry weight humectant and ispresent in amounts between 1 and 4 pounds per 1000 square feet.

A more specific example of a preferred embodiment of the FSK facingsheet material laminate 20 includes: a) 45 lb/3000 ft² alkaline paper(AKD) layer 22 with cationic wet end starch, CaCO₃/TiO₂ filled,ethylated starch, and a fluorinated compound such as Aquapel® (marketedby PPG industries) at size press, which would contain between about 70%and about 90% by weight cellulose fibers and between about 10% and about30% by weight glass fibers having a mean diameter between about 0.6microns and about 4 microns (e.g. micro-strand glass fibers having amean diameter of about 0.65 microns, about 2.7 microns, or about 4.0microns); b) 13 lb/3000 ft² vinylidene chloride/butadiene copolymerlatex adhesive 28 wherein the latex adhesive contains 7 lb/3000 ft²adhesive additives in the following approximate percentages by weight29% antimony, 26% decabromo diphenyl ether (decabrom), 9% magnesiumhydrate, and 36% aluminum trihydrate; c) glass fiber scrim 24; and analuminum foil layer 26. The use of a water repellant compound, such asAquapel® (marketed by PPG industries), which is typically applied as acoating on the outer facing surface of the paper composite sheet duringthe paper making process, provides the paper composite sheet with moreuniform absorption characteristics and enhances the application ofsurface coatings such as the humectant containing surface coatings andnon-humectant containing surface coatings discussed above that can beapplied to the exposed surface of the paper composite sheet of the papercomposite sheet layer 22 to impart strength, stiffness and/or water,oil, and grease resistance to the paper.

In addition to providing greater dimensional stability and stiffness andreduced deformation and wrinkling, the use of a paper composite sheetlayer 22 containing glass fibers in the preferred embodiments of the twopreceding paragraphs should enhance the flame spread resistance of theFSK facing sheet material laminate 20. While glass fibers melt, they donot burn like cellulose fibers. Thus, these embodiments of FSK facingsheet material laminate 20 should be able to pass the relevant ASTMflame spread tests with reduced amounts of flame retardant additives andoffer the potential of a lower cost, more environmentally friendly flameretardant FSK facing sheet material laminate.

Laboratory hand sheet samples were made using various concentrations ofglass and/or other synthetic fibers in conjunction with the standardpaper fiber pulp of a bleached kraft paper normally used for a papersheet layer of a standard foil/scrim kraft facing sheet material. Thesehand sheet samples were compared to control hand sheet samples made ofthe standard paper fiber pulp for lamination curl and paper stress. Whenexposed to conditions of high heat and humidity (e.g. temperatures of75° F. or greater and relative humidities of 50% or greater), all of thepaper sheet layer formulations that included synthetic fibers exhibitedimproved dimensional stability and reduced wrinkling when compared tothe control hand sheet samples. The following tested formulations are byweight:

-   -   1. Control (100% Fraser Paper Stock with no additives)    -   2. 90% Fraser Paper Stock/10% SWP Fybrel® PE        FYB-E400—MiniFibers, Inc.    -   3. 80% Fraser Paper Stock/20% SWP Fybrel® PE        FYB-E400—MiniFibers, Inc.    -   4. 90% Fraser Paper Stock/10% PET Dry—MiniFibers, Inc.    -   5. 80% Fraser Paper Stock/20% PET Dry—MiniFibers, Inc.    -   6. 95% Fraser Paper Stock/5% JM Micro-Strand™ 90-475 glass        microfibers    -   7. 90% Fraser Paper Stock/10% JM Micro-Strand™ 90-475 glass        microfibers    -   8. 95% Fraser Paper Stock/5% JM Micro-Strand™ 100-475 glass        microfibers    -   9. 90% Fraser Paper Stock/10% JM Micro-Strand™ 100-475 glass        microfibers    -   10. 95% Fraser Paper Stock/5% JM Micro-Strand™ 106-475 glass        microfibers    -   11. 90% Fraser Paper Stock/10% JM Micro-Strand™ 106-475 glass        microfibers    -   12. 90% Fraser Paper Stock/5% PET Dry/5% JM Micro-Strand™ 90-475        glass microfibers    -   13. 90% Fraser Paper Stock/5% PET Dry/5% JM Micro-Strand™        100-475 glass microfibers    -   14. 90% Fraser Paper Stock/5% PET Dry/5% JM Micro-Strand™        106-475 glass microfibers    -   15. 90% Fraser Paper Stock/5% SWP Fybrel® PE FYB-E400/5% JM        Micro-Strand™ 100-475 glass microfibers

The jacketed tubular pipe insulation assembly 40 of FIG. 2 includes atubular piece of pipe insulation 42 and a jacket 44. While the tubularpiece of pipe insulation 42 may be made of other insulating materials,preferably, the tubular piece of pipe insulation 42 is made of glassfibers that are bonded together with a thermosetting resin. The jacket44 is made of a sheet of the facing material 20 of the subjectinvention.

The tubular piece of pipe insulation 42 has a longitudinally extendingslit 46 that passes completely through the tubular wall of the pipeinsulation on one side and into the interior of and part of the waythrough the tubular wall of the pipe insulation on the opposite side ofthe pipe insulation so that the pipe insulation 42 and thus the jacketedtubular pipe insulation assembly 40 can be opened, passed over, andclosed about a pipe. The jacket 44 of the jacketed pipe insulationassembly 40 is wrapped circumferentially about the tubular piece of pipeinsulation 42 so that the longitudinal edge portion 48 of the jacket 44and the sealing tab 50 of the jacket extend adjacent, parallel to, andon opposite sides of the slit 46, but do not overlap the slit 46. Thesealing tab typically has a pressure sensitive adhesive layer 52 thereonthat is overlaid and protected from degradation before sealing by aremovable silicone treated release sheet 54. Once the jacketed tubularpipe insulation assembly 40 is placed on a length of pipe, the releasesheet 54 is removed from the adhesive layer 52 and the sealing tab 50 isplaced over the slit 46 and adhesively sealed to the longitudinal edgeportion 48 of the jacket 44 by the adhesive layer 52 to seal thejacketed pipe insulation assembly 40 about the pipe.

These jacketed tubular pipe insulation assemblies 40 are commonlyinstalled on the pipes of hot and cold piping systems to retard the flowof heat between the pipes of the systems and the ambient environment andconserve energy. The jackets 44 of the jacketed tubular pipe insulationassemblies 40 enhance the performance of the pipe insulation (e.g.retard the transmission of water vapor); prevent the pipe insulationfrom being exposed to contaminants; make the pipe insulation moreaesthetically pleasing; protect the pipe insulation from adverseclimatic conditions; and serve as a means for securing and sealing thejacketed tubular pipe insulation assemblies 40 in place on the pipes ofthe piping systems. The tubular pieces of pipe insulation 42 and hencethe jacketed tubular pipe insulation assemblies 40 typically: range inlength from about 36 inches (about 0.92 m) to about 48 inches (about1.22 m); have a wall thickness ranging from about 0.5 inches (about 13mm) to about 3 inches (about 76 mm); and range in outside diameter fromabout 2 inches (about 50 mm) to about 23 inches (about 600 mm).

In describing the invention, certain embodiments have been used toillustrate the invention and the practices thereof. However, theinvention is not limited to these specific embodiments as otherembodiments and modifications within the spirit of the invention willreadily occur to those skilled in the art on reading this specification.Thus, the invention is not intended to be limited to the specificembodiments disclosed, but is to be limited only by the claims appendedhereto.

1. A facing for insulation products, comprising: a laminate comprising:a foil or metallized polymeric film sheet layer forming an inner layerof the laminate that is adapted be bonded directly to a surface of aninsulation product; a paper composite sheet layer forming an outerexposed layer of the laminate; a scrim intermediate the foil ormetallized polymeric film sheet layer and the paper composite sheetlayer; an adhesive bonding the foil or metallized polymeric film sheetlayer, the paper composite sheet layer and the scrim together; and ahumectant to absorb moisture such that the absorption of moisture byfibers of the paper composite sheet layer is inhibited to therebyprovide the paper composite sheet layer with greater dimensionalstability and reduce wrinkling of the paper composite sheet layer whenthe laminate is exposed to conditions of high humidity.
 2. The facingfor insulation products according to claim 1, wherein: the papercomposite sheet layer comprises cellulose fibers.
 3. The facing forinsulation products according to claim 2, wherein: the paper compositesheet layer includes synthetic and/or inorganic fibers.
 4. The facingfor insulation products according to claim 1, wherein: the papercomposite sheet layer comprises synthetic and/or inorganic fibers. 5.The facing for insulation products according to claim 1, wherein: thepaper composite sheet layer of the laminate comprises between 0.1% and10% by dry weight the humectant.
 6. The facing for insulation productsaccording to claim 5, wherein: the humectant is contained within a papercomposite sheet of the paper composite sheet layer.
 7. The facing forinsulation products according to claim 5, wherein: the humectant is atleast partially contained in a coating on a paper composite sheet of thepaper composite sheet layer.
 8. The facing for insulation productsaccording to claim 5, wherein: the humectant is at least partiallycontained within the adhesive bonding the foil or metallized sheetlayer, the scrim, and the paper composite sheet layer together.
 9. Thefacing for insulation products according to claim 5, wherein: thehumectant is at least partially contained in a coating on an outersurface of a paper composite sheet of the paper composite sheet layer.10. The facing for insulation products according to claim 5, wherein: apaper composite sheet of the paper composite sheet layer includesbetween 70% and 90% by weight cellulose fibers and between 10% and 30%by weight synthetic and/or inorganic fibers.
 11. The facing forinsulation products according to claim 5, wherein: the paper compositesheet layer includes between 0.5% and 25% by dry weight flame retardant.12. A faced insulation product comprising: an insulation componenthaving a surface; and a facing laminate bonded to the surface of theinsulation component; the facing laminate comprising: a foil ormetallized polymeric film sheet layer forming an inner layer of thelaminate that is adapted be bonded directly to a surface of aninsulation product; a paper composite sheet layer forming an outerexposed layer of the laminate; a scrim intermediate the foil ormetallized polymeric film sheet layer and the paper composite sheetlayer; an adhesive bonding the foil or metallized polymeric film sheetlayer, the paper composite sheet layer and the scrim together; and ahumectant to absorb moisture such that the absorption of moisture byfibers of the paper composite sheet layer is inhibited to therebyprovide the paper composite sheet layer with greater dimensionalstability and reduce wrinkling of the paper composite sheet layer whenthe laminate is exposed to conditions of high humidity.
 13. The facedinsulation product according to claim 12, wherein: the paper compositesheet layer comprises cellulose fibers.
 14. The faced insulation productaccording to claim 13, wherein: the paper composite sheet layer includessynthetic and/or inorganic fibers.
 15. The faced insulation productaccording to claim 12, wherein: the paper composite sheet layer of thelaminate comprises between 0.1% and 10% by dry weight the humectant. 16.The faced insulation product according to claim 15, wherein: thehumectant is contained within a paper composite sheet of the papercomposite sheet layer.
 17. The faced insulation product according toclaim 15, wherein: the humectant is at least partially contained in acoating on a paper composite sheet of the paper composite sheet layer.18. The faced insulation product according to claim 15, wherein: thehumectant is at least partially contained within the adhesive bondingthe foil or metallized sheet layer, the scrim, and the paper compositesheet layer together.
 19. The faced insulation product according toclaim 15, wherein: the humectant is at least partially contained in acoating on an outer surface of a paper composite sheet of the papercomposite sheet layer.
 20. The faced insulation product according toclaim 15, wherein: a paper composite sheet of the paper composite sheetlayer includes between 70% and 90% by weight cellulose fibers andbetween 10% and 30% by weight synthetic and/or inorganic fibers.
 21. Thefaced insulation product according to claim 15, wherein: the papercomposite sheet layer includes between 0.5% and 25% by dry weight flameretardant.
 22. The faced insulation product according to claim 12,wherein: the insulation component is a piece of pipe insulation; thepipe insulation comprising: a tubular core of fibrous insulation havinga length and a longitudinal axis; the tubular core having asubstantially cylindrical outer surface; the tubular core having asubstantially cylindrical inner surface; the tubular core having a wallextending between the cylindrical outer surface and the cylindricalinner surface; the wall of the tubular core having a radially extendingthickness; the wall of the tubular core having a first slit extendingcompletely there through; the first slit extending parallel to thelongitudinal axis of the tubular core for the length of the tubularcore; the tubular core having a second slit in the inner surface of thetubular core; the second slit being substantially opposite the firstslit; the second slit extending parallel to the longitudinal axis of thetubular core for the length of the tubular core; and the second slitextending only partially through the wall of the tubular core to form alongitudinally extending hinge in the tubular core that permits thetubular core to be opened and closed to place the tubular core about apipe; and the facing laminate is coextensive with and bonded to thesubstantially cylindrical outer surface of the tubular core and flexibleso that the tubular core with the facing can be opened, placed about apipe, and closed without degrading the facing laminate.
 23. A facing forinsulation products, comprising: a laminate comprising: a foil ormetallized polymeric film sheet layer forming an inner layer of thelaminate that is adapted be bonded directly to a surface of aninsulation product; a paper composite sheet layer forming an outerexposed layer of the laminate; a scrim intermediate the foil ormetallized polymeric film sheet layer and the paper composite sheetlayer; an adhesive bonding the foil or metallized polymeric film sheetlayer, the paper composite sheet layer and the scrim together; and ahumectant, the paper composite sheet layer comprising a paper compositesheet having between about 70% and 90% by weight cellulose fibers andbetween about 10% and 30% by weight synthetic and/or inorganic fibers tothereby provide the paper composite sheet layer with greater dimensionalstability and reduce wrinkling of the paper composite sheet layer whenthe laminate is exposed to conditions of high humidity.
 24. The facingfor insulation products according to claim 23, wherein: the syntheticand/or inorganic fibers of the paper composite sheet of the papercomposite sheet layer are glass fibers having a mean diameter betweenabout 0.6 and about 4 microns.
 25. The facing for insulation productsaccording to claim 24, wherein: the paper composite sheet layer of thelaminate comprises between 0.1% and 10% by dry weight the humectant. 26.The facing for insulation products according to claim 25, wherein: thehumectant is contained within the paper composite sheet of the papercomposite sheet layer.
 27. The facing for insulation products accordingto claim 25, wherein: the humectant is at least partially contained in acoating on the paper composite sheet of the paper composite sheet layer.28. The facing for insulation products according to claim 25, wherein:the humectant is at least partially contained within the adhesivebonding the foil or metallized sheet layer, the scrim, and the papercomposite sheet layer together.
 29. The facing for insulation productsaccording to claim 25, wherein: the humectant is at least partiallycontained in a coating on an outer surface of the paper composite sheetof the paper composite sheet layer.
 30. The facing for insulationproducts according to claim 25, wherein: the paper composite sheet layerincludes between 0.5% and 25% by dry weight flame retardant.
 31. A facedinsulation product comprising: an insulation component having a surface;and a facing laminate bonded to the surface of the insulation component;the facing laminate comprising: a foil or metallized polymeric filmsheet layer forming an inner layer of the laminate that is adapted bebonded directly to a surface of an insulation product; a paper compositesheet layer forming an outer exposed layer of the laminate; a scrimintermediate the foil or metallized polymeric film sheet layer and thepaper composite sheet layer; an adhesive bonding the foil or metallizedpolymeric film sheet layer, the paper composite sheet layer and thescrim together; and a humectant, the paper composite sheet layercomprising a paper composite sheet having between about 70% and 90% byweight cellulose fibers and between about 10% and 30% by weightsynthetic and/or inorganic fibers to thereby provide the paper compositesheet layer with greater dimensional stability and reduce wrinkling ofthe paper composite sheet layer when the laminate is exposed toconditions of high humidity.
 32. The faced insulation product accordingto claim 31, wherein: the synthetic and/or inorganic fibers of the papercomposite sheet of the paper composite sheet layer are glass fibershaving a mean diameter between about 0.6 and about 4 microns.
 33. Thefaced insulation product according to claim 32, wherein: the papercomposite sheet layer of the laminate comprises between 0.1% and 10% bydry weight the humectant.
 34. The faced insulation product according toclaim 33, wherein: the humectant is contained within the paper compositesheet of the paper composite sheet layer.
 35. The faced insulationproduct according to claim 33, wherein: the humectant is at leastpartially contained in a coating on the paper composite sheet of thepaper composite sheet layer.
 36. The faced insulation product accordingto claim 33, wherein: the humectant is at least partially containedwithin the adhesive bonding the foil or metallized sheet layer, thescrim, and the paper composite sheet layer together.
 37. The facedinsulation product according to claim 33, wherein: the humectant is atleast partially contained in a coating on an outer surface of the papercomposite sheet of the paper composite sheet layer.
 38. The facedinsulation product according to claim 33, wherein: the paper compositesheet layer includes between 0.5% and 25% by dry weight flame retardant.39. The faced insulation product according to claim 31, wherein: theinsulation component is a piece of pipe insulation; the pipe insulationcomprising: a tubular core of fibrous insulation having a length and alongitudinal axis; the tubular core having a substantially cylindricalouter surface; the tubular core having a substantially cylindrical innersurface; the tubular core having a wall extending between thecylindrical outer surface and the cylindrical inner surface; the wall ofthe tubular core having a radially extending thickness; the wall of thetubular core having a first slit extending completely there through; thefirst slit extending parallel to the longitudinal axis of the tubularcore for the length of the tubular core; the tubular core having asecond slit in the inner surface of the tubular core; the second slitbeing substantially opposite the first slit; the second slit extendingparallel to the longitudinal axis of the tubular core for the length ofthe tubular core; and the second slit extending only partially throughthe wall of the tubular core to form a longitudinally extending hinge inthe tubular core that permits the tubular core to be opened and closedto place the tubular core about a pipe; and the facing laminate iscoextensive with and bonded to the substantially cylindrical outersurface of the tubular core and flexible so that the tubular core withthe facing can be opened, placed about a pipe, and closed withoutdegrading the facing laminate.
 40. The facing for insulation products ofclaim 1, wherein the humectant comprises at least one substance selectedfrom the group consisting of glycerin, ethylene glycol, polyethyleneglycol, and isopropylene glycol.
 41. The faced insulation product ofclaim 12, wherein the humectant comprises at least one substanceselected from the group consisting of glycerin, ethylene glycol,polyethylene glycol, and isopropylene glycol.
 42. The facing forinsulation products of claim 23, wherein the humectant comprises atleast one substance selected from the group consisting of glycerin,ethylene glycol, polyethylene glycol, and isopropylene glycol.
 43. Thefaced insulation product of claim 31, wherein the humectant comprises atleast one substance selected from the group consisting of glycerin,ethylene glycol, polyethylene glycol, and isopropylene glycol.